STEERING SYSTEM STEERING WHEEL AND COLUMN STEERING WHEEL STEERING LOCK STEERING COLUMN (Model 160 series) MANUAL STEERING GEAR (Model © \VRB70L) —Model 160 series— MANUAL STEERING GEAR (Model : VRB7OL) —Model 61 series— POWER STEERING GEAR (Mode! 1.P.S. S6L) AND OIL PUMP s arate SYS a CONTENTS ST. 2 STEERING LINKAGE ST 3 SERVICE DATA AND ST 3 SPECIFICATIONS st. 3 GENERAL SPECIFICATIONS sta INSPECTION AND ADJUSTMENT TIGHTENING TORQUE ST6 TROUBLE DIAGNOSES AND CORRECTIONS sT10 SPECIAL SERVICE TooLS sTa2 stat 81.23 sT23 st.23 sT28 $1.25 sT27‘Steering System ~ STEERING SYSTEM STEERING SYSTEM sO, 86-98) 96-96 1 Sug ‘nyo Buses st2STEERING WHEEL REMOVAL. 1. Disconnect battery ground cable Remove horn pad and steering wheel nut “Model 160 Series ‘Model 61 Series ae urn counterclockwise sssr262 3. Remove steering wheel using Tort CAUTION: Do not strike end of steering column Shaft with a hammer. Striking shaft will damage bearing or column shaft. STEERING SYSTEM — steering Wheel and Column STEERING WHEEL AND COLUMN INSTALLATION Install steering wheel in the reverse ‘order of removal. Observe the follow: ing instructions, 1. Apply grease to sliding portions Siding portion ssT109| 2. Install steering wheel on column shaft ina. straightahead position. 3 installing steering wheel, turn it clockwise and counterclock: wise, checking for catch or drag. Also check horn operation. STEERING LOCK REMOVAL Before removing steering lock, dis connect battery ground cable. 1. Remove steering column shell 2. Break selfshear type serews with 2 drill or other appropriate tool. 3. Remove screws and disconnect, steering lock, Seltshear type sew INSTALLATION Align steering lock hole in steering column tube with mating portion of steering lock 2. Install screws and self-shear type ‘Screws and then cut off selfshear type screw heads st3‘Steering Whee! and Column ~ STEERING SYSTEM STEERING COLUMN (Model 160 series) Collapibie type: Hardtop and Station Wagon oe : Bele tpt Be vate Steering columa — shaft assembly /- Sea ving Steering tok “ ~ Pain washer sembly 34-44 (035-048,25-339 >. Ois-2 15-22,11 16>) Hs em / — Jacket tube assembly 13-1813 -18,9-19) To instrument pane lower side ~@ 34 -44,(035-045,25-33) 1 39-49 4.0-50,29-3 To dash pane, @: No them, 8) | REMOVAL 3. Remove steering column shell 6, Remove column mounting coven. bracket 4 Remove, bolt securing column "Remove combination switch as shaft and rubber coupling. Rares Refer to Section EL. 5. Remove jacket tube bracket from dash panel 2. Remove steering wheel. Refer to Steering Wheel 7. Draw out steering column sss bly from room side, sT.4INSTALLATION Install steering column in reverse order of removal 1 Set wheels in a straight-ahead position. 2, Fit steering column assembly on to worm shaft Carefully install so that punch mark st top end of column shaft faces upward, 3. After sliding jacket tube bracket to dash panel, tighten nuts to retain + Jacket tube bracket to dash panel 3.4-4.4Nm (0.35 - 0.45 kgm, 25-3.3 feb) 4. Tighten column mounting bracket te_ rary 5, Tighten column shaft securing bolts temporarily to support upper side of steering column assembly. 6. Tighten column shaft securing bolts and then tighten column mount- ing bracket securing bolts + Rubber coupling to column shaft 39-49Nm (4.0-5.0 kom, 29- 36 ft1b) ‘Column mounting bracket 13-18N-m (1.3.1.8 kgm, 9-13 felb) CAUTION: a. Make sure that any undue stress is, applied to rubber coupling b. To avoid damaging bolt or serra tions, align groove in worm shaft with bolt hole in rubber coupling, 7. Install steering wheel. Refer to Stering Wheel. 8. After installation, make sure that Seering wheel turns smoothly. STEERING SYSTEM ~ Steering Wheel and Column DISASSEMBLY 1. Remove rubber coupling assem by. 2. Remove steering lock assembly, Refer to Steering Lock for removal 3. Compress steering column spring with wires. 7 ae SS 4 ing whee! fixing collar, snap ring, plain washer, steering column spring and spring seat. 1 Collar wire 2 Steering wheel colar 3. Snap ring 4 Phin washer Steering column spring 6 7 5. Pull column shaft out. CAUTION: Be careful not to damage upper and lower bearings into column tube, ASSEMBLY ‘Assemble steoring column in the re- verse order of disassembly. Observe the following notes. Apply recommended multi-purpose grease to column bearings, spring, and other sliding parts, CAUTION: Be careful to prevent interference with remote control lever bracket, © Be careful not to give impact force fr abnormally strong force in axial direction to steering column shaft. © Snap ring for column shaft should rot be reused. INSPECTION When steering wheel will not turn smoothly, check the steering column for the following matters and replace malfunctioning parts 1. Check column bearing for damage ‘or unsmoothness. If so, lubricate with recommended multi-purpose grease or replace with a new one as jacket tube assembly. 2. Check jacket tube for deforma: tion or breakage, and replace if neces: sary. 3. Check column spring, and replace if damaged or weakened, Sts“Manual Stooring Gear (Model: VRB70L) ~Mode! 160 series ~ STEERING SYSTEM MANUAL STEERING GEAR (Model : VRB7OL) —Model 160 series— Lack nut D 29-393.0-4.0, 2-29) Filler plug é LZ -@ 15-25 (1.8-25,11-18) oe I & Sector shat cover Casket Sector shaft adjusting sim Refer 0 SDS B31-360.2-32,28-2) SB sector start sgnnengscrey 9 ose ‘When adjusting backlash, se Once removed, oi seal ee cane — i, \ | wg ann Sattt | ee ac ie | pe ve a. | Ss etn Reterto SDS XN ‘Ball nut and worm assembly Be crf not tallow tall ot o rundown to ether end of End tal uies wie danaed if at ott nt it oat | tops end ot worm ‘Once removed, oil seal © Do not detach ball nut from worm shaft assembly. at torteuied an, I eceny pice al mt end worm sey with str @ © 235-25 — eo (24.0 - 27.0, 174-195) Ds Nm chem, 140) ss REMOVAL AND INSTALLATION Mor ato be oun Oo wuo 309 30 ‘Aen he rove in wom sat theta ein robersurine Mes yoke an pr colin bol thowp th and ct wet ot coma Guar housing Tottane | DM-96 | Geos, | oo | ® 83-108 Toplinn trons ci twopelenme” 235,265 a! 0,65-00 ‘of sector shaft serrations, and nee inca a hen pi wer @: Nemceem, tein) ea soraso sts areeae BP aeSTEERING SYSTEM ~ Manual Stooring Gear (Model: VRB70L) -Model 160 series ;— DISASSEMBLY Before dianembling by hand, make ure extra te clean aod fet trom dust and_ dit. and throughty drain guar tid by removing filer ohn I. lice sering gear ina vie sing Tool KV48100901 in place oe 2.” Set worm gear in staight head Ls poston K MOTE 5. Remove sector shaft cover from sector shaft, 6. Remove sector shaft oil seal, if necessary. Scxewdriver 3. Remove sector shaft cover fixing bolts 8. Draw out worm gear with worm 4. Remove sector shaft with sector he # shaft cove. ial CAUTION: CAUTION: 4. Be careful not to allow ball nut to & When pullling sector shaft out, be careful not to damage oil seal or associated parts, b. Set worm gear in a straight ahead down to either end of worm. nds of ball guides will be damaged if nut is rotated until it stops at end of worm, Position, }. Do not detach ball nut from worm © Do not remove sector shaft bearing shaft assembly. {rom stering gear housing. If neces. IF necessary, replace entire unit as S21, replace gear housing assembly. an assembly. er reine EEE ‘Gasket and worm bearing shims 9. Remove oil seal from rear cover. ‘Once removed, oil seal must not be ‘sed again, ASSEMBLY AND ADJUSTMENT '* Before assembling and adjusting by hhand, make sure each partis clean and lubricate with gear fluid. © Fill space between sealing lips of ‘new sector shaft and adjusting plug oil seals with recommended multi ‘purpose grease, Worm by ring preload 1. Fit worm gear assembly with worm bearing in gear housing strMansel Steering Gear (Model: VRB70L) ~Model 160 series 2. Install rear cover on gear housing with gasket and worm bearing shims. ‘Standard shim thickness: 1.0 mm (0.039 in) Available worm bearing shims: Rofer to $.0.S. «Gated orm easing sins ——~ Lie DUN (8.23.7 kgm, 23-27 438) = [ Lonel yi Z Jes 3. Adjust using Tools, @ Rotate worm shaft @ few turns in both directions to correctly settle worm bearing and measure preload © When adjusting worm bearing pre- Toad, add or remove shims until cor- ‘ect adjustment is achieved. worm bearing preload 'ST31278000 Sector shaft end play Select suitable adjusting shim and adjust end play between sector shaft and adjusting screw. STB Sector shaft adjusting screw shims Refer to S.0.S. ‘Adjusting shi awe ‘Sector shaft end o (0.01 -0.03 mm {0.0004 «0.0012 in) Steering gear preload 1. Press oil seal to steering gear hhousing using Tool. Before pressing oil seal, coat seal contacting face of oil seal with gear fluid. 2. Install sector cover on adjusting screw with sector shaft Adjusting serew roo 3. Set worm gear in a straight-ahead position 4. Insert sector shaft and sector cover assembly with gasket into ear housing, STEERING SYSTEM Carefully insert sector sh tt place, using care not to scratch oil wn lsu. Caster 5. Tighten sector cover 10 pew housing. 7 6. Adjust backlash as shown in illustration, Rotate worm goar a few turns in both ditections to settle down steering gear and in straight ahead position, land then measure backlash at gear arm top end. 0-0.2mm(0-0.008in) craigSTEERING SYSTEM — Menval Steering Gear (Model: VRB70L) ~Mode! 160 series— 7, Measure total gear preload in straight-ahead position, | | 7 STRTTSDOO ‘otal ear proud: (eh it an) Less than 1.23 Nom (125 kg-em, 10.9 nt) INSPECTION Wash clean all the disassembled parts in solvent and check for condi: tion. Sector shaft 1. Check gear tooth surface for pitting, burrs, cracks or any other Gamage, and replace if necessary 2. Check sector shaft for fon its serration, and replace if neces: sary. Also check gear housing for deformation sortion Steering worm assembly 1. Inspect ball nut gear tooth sur- face, and Yeplace if pitting, burrs, wear or any other damage is found, 2. Ball nut must rotate smoothly on worm gear. If found too tight, assem bly should be replaced, Check rotation of ball nut as follows: () Move ball nut to either end of worm gear, and gradually stand ‘worm shaft and ball nut assembly until ball nut moves downward on worm gear under its own weight. Downward own weight sero0e (2) If ball nut does not move freely over entire stroke, replace assembly. Be careful not to damage ball nut ‘uide tube while check is being made, CAUTION: Be careful not to allow ball nut to run down to either end of worm. Bearing 1. Inspect worm bearing for wear, pitting or any other damage. Replace as requried, When replacing worm bearing, replace it as a set of bearing and outer race. 2. If sector shaft needle bearings are wom or damaged, replace as an as- sembly of gear housing and bearings. Oil seals Discard any oil seal which has once been removed. Replace oil seal if sealing lip is deformed or cracked. ‘Also discard oil seal if spring is fa tigued or dislocated sto‘Manuel Steering Gear (Model: VRB7OL) ~Mode! 61 sories- ~ STEERING SYSTEM MANUAL STEERING GEAR (Model : VRB7OL) —Model 61 series— Worm bearing shims — When adjusting worm Refer to SDS. ‘bearing preload, use it. | (24.0-27.0, 174-195) Worm bea ng Loa sea Removed ol seal must not te used agin Ball aut and worm assembly ——___—— flBe careful not to allow all nut to run down to sither end of worm: ‘¢ Ends of bal guides will be damaged if tis stated until stops at end of worm. ‘¢ Domot detach tall mat from wort shaft assembly Ti necessary, replace ball nut and worm asembly ‘with sector shat. ‘Sector shaft adjusting screw ‘When adjosting backlash, use i ‘Stoering gar housing, Sector sha {1 gjning shin Lock aut. Z S Si i Gets. Faso Filer plug HC BD: Na them, 10) REMOVAL AND INSTALLATION ‘© Alternator 6. Remove pitman arm, ‘¢ Radiator shroud attaching bolts Remove following parts. Steering wheel Steering shell cover Combination switch ‘Steering column mounting bracket Loosen combination meter cover. Jack up front of vehicle and sup- tit on safety stands. Block rear wheels with chocks. Remove following parts. (© Harness connectors at alternator and water temperature sensor pagupeceen sT-10 Gear housing — Gear arm 7 —~ 729020001STEERING SYSTEM — Manual Steering Gear (Model: VRB70L) ~Model 61 series 7. Remove bolts securing gear box. 8. After removing steering lock, ex. tract steering gear from under vehicle body. DISASSEMBLY Before disassembling steering gear, make sure external is clean and free from dust and dirt, and thoroughly drain gear fluid by removing filler plug. For disassembly, refer to Manual Steering Gear (Model: VRB7OL) Model 160 Series—. However, note the following additional instruction. ‘© Placing steering gear ina vse. ASSEMBLY AND ADJUSTMENT © Before assembling and adjusting, make sure each part is clean and lubricate with gear fluid. © Fill space between sealing lips of fnew sector shaft and rear cover oil seals with recommended multipur- pose grease. Refer to Manual Stocring Gear (Model: VRB7OL) —Model 160 Series. INSPECTION Refer to Manual Steering Gear (Model: VRB70L) —Model 160 Series. stnpower Steering Gear (Model: I.P.S. 561) and Oi! Pump ~ STEERING SYSTEM. POWER STEERING GEAR (Model : I.P.S. 56L) AND OIL PUMP DESCRIPTION The integral power steering unit isa components are as follows: Power steering ‘gear housing into which a control valve © Oil pump ‘The power steering gear is licensed —_(2-spool valve type) and power cylin. @ Power steering gear by ZF company in West Germany. der are built compactly. The major Oil piping 4 @ 19-25 0.9-26, 18-19) pump assembly 39-49 pace (40-50.29-307 0-50, 22-36) | 39-49 (40-5.0,29-36) a © 4-96 ee (86-58,62-7) | Loe aru (14-18, 101-130) Low pressu howe ad pi SS Ds Nm kgm, 1d) Power steering gear CAUTION: ©. Should disassembly of integral ‘The intgral power steering gears a, The parts which can be disaszem- BOWE steering oar remain un. ini indicat it sn accurate of! prewar mestans. "Bada stongyrastice, and‘ fr any reason, nite In disassembling it, be careful to keep never disassemble other parts than parts with a clean cover dust, iron powder and other foreign ‘the specified ones. If parts not ne particles out ofthe gear housing indicated in the manual are also Hands shouldbe cleaned imme Only the sealing parts of the gear disassembled, replace the assembly. D0 "not use a ray. Be sure t0 Use assembly can be replied. The reain- instead of reassembling those pars, D0 704 wm 8 ra ing parts must be replaced as an gear _b. Disassembly of integral power st prt on : assembly. ing geor shoald be performed in a 2 mare te follew procedures and cautions indicated in the Service i place as clean as possible, although lusaal: a dust preventing device is not re- ‘quired. sT-12=| | i le (io rear cover) 03-33, 17-2) *: Once removed, must not be used again Bs Nm kgm, 14) 8 pump Malfunctioning (Replace as an oil Pump assembly), STEERING SYSTEM — Power Steering Gear (Model: .P.S. 561) and Oil Pump sig en So / on @ 28-3429-35,21-25) ® “topper washer oak Geers @ eo Sector shaft adjusting shim Sector shaft adjusting — a4 Sector shaft s0sing Between sector cover and gear housing ~ *Special washer “A” — ene oe ou _— "Dot seal an Nut @ 137-1774 -18, 101 -130) “To gear arm and sector shaft sT-13Power Steering Geer (Model: IS. 56L) and Oil Pump ~ STEERING SYSTEM. REMOVAL Before removing, clean exteriors of gear housing and oil pump with steam and dry with compressed air. Steering gear © lug openings of gear housing, and securely locate hose connectors at {position higher than oll pum and cover with rg. ‘¢ Be extremely careful to prevent enty of foreign matter into hoses though Howe to gear housing 39-49 (40-50,29-36) Rubber coupling to stub shaft B 39-49 (4.0-5.0, 29.36) — Sector shaft to gear arm @ 137-177 44-18, 101-130) ‘© Remove gear am, Gear housing to body D 84-96 (86-98, em ‘5129020001 (© Install gear am Align four grooves of gear arm serrations with four projections of sector shaft serrations and install and tighten lock washer and nut Ds Nem (keen, tb) Removing points ssvaee Oil pump and each hose 5. Disconnect hoses from pump, 6. Remove oil pump brackets and other brackets from engine. 7. Unfasten hose clamps, and remove hoses from suspension crossmember, 1, Turn belt adjusting bolt counter: clockwise INSTALLATION AND ei ADJUSTMENT 2. Remove oil pump belt, 3. Loosen (not remove) hoses at pump. Install steering gear in the reverse order of removal st-14Fluid tevel 1. Check fluid level in reservoir, ob. serving dipstick when fluid is cold ox. “aad ‘# Do not overfill with fluid, ‘¢ Normal operating temperature is 60 t0 80°C (140 to 176°F), ‘© When running engine, make sure fluid level variations in opening oil ‘pump are less than 2 mm (0.08 in) 2. Check fluid level and leakage. Recommended fluid is Autom: Transmission Fluid.” mended Lubricant”. Fluid capacity (With oil pump, each hove and steering gear assembly): ‘Approximately 750 - 950 me (26.4- 33.4 Imp fl oz) Pump belt adjustment Adjust oil pump belt tension, \ him’ presse At ol 8-12 mmm (0.31 - 0.47 in) sst26 STEERING SYSTEM — rower Steering Gear (Model: IPS. 56L) and Oi! Pump Check fluid leakage 1. Rum engine at idle speed or 1,000 pm. Make sure temperature of fluid in pump rises to 60 to 80°C (140 to 176°F) with a temperature indicator. 2. Tum steering wheel to right-t: left several times, 3. Hold steering whee! at each “lock” Position for five seconds and carefully check the following points for fluid leakage. © Oilseal at rear cover Intermediate cover ‘Adjusting serew lock nut ‘Sector shaft oll seal Sector cover O-ring Ol pressure line connectors CAUTION: Do not hold steering wheel at lock position for more than fifteen seconds Hydraulic system check To determine whether problem is in steering gear or oil pump, measure ‘operating pressure, Before conducting hydraulic system ‘test, carefully check belt tension and condition of driving pulley. Tires must be inflated to normal pressure. 1. Check fluid level and fluid leak age, adding oil if necessary 2. Runengine. Make sure temperature of fluid in pump rises to 60 to 80°C (140 to 176°F) with a temperature indicator. 3. Stop engine 4. Set Tool. (© Gauge must be between shut-off valve and oil pump. | Pressure gauge calibrates: 19,807 KPa (98-1 bar, 100 ka/em?, ©) amy) ssro09| To oi pump out 5. Open shutoff valve at Tool 6. Check fluid level, adding fluid if necessary, 7. Run engine at idle for 3 t0 5 seconds. 8. Stop engine and check Muid level, adding fluid if necessary 9. Run engine and check fluid level again, adding oil if necessary. 10, Turn steering wheel fully in left or tight until uid reaches operating temperature. © Be sure that all connections are tight, ‘© Expel any sir from system, I. Slowly close shutoff valve with steering wheel fully turned in left or right and lightly touch whee! stopper. CAUTION: - Do not close shutoff valve for more ‘than fifteen seconds, as this would abnormally increase lubricant tem- perature and cause undue pump wear. stPower Steering Gear (Model: IP.S, 56L) and Oi Pump - STEERING SYSTEM With valve fully closed, pump pres: 9. Stop engine and cool fluid. Check 3. Check steering wheel turning tor. a geld eal ania fuid level, adding fluid if necessary que when steering wheel has bees tured 360° from straightahead pos, Normal pressu ‘© Operation should be performed, ‘ion 6,865 kPe (68.6 bar, making sure that fluid level is kept 70 ka/em? , 996 psi) at idling within specified limit. cee ‘Less than 34.3 N (3.5 kg, 7.7 ib) @ Repeat this operation until air 12. If pressure increases beyond upper bleeding is completed. Seren eee nerer a Sil limit, pressure relief valve in oil pump 10. If air cannot be bled completely is not functioning properly. Replace asin steps 1 through 9, proceed as fol oil pump assembly, lows: 13. If, with shut-off valve fully closed, (1) With engine runing at 1,000 to pressure drops below lower limit, the 1,500 rpm, repeat step 9. problem is in pump. Replace as oil (2) Tum steering wheel to right and pump assembly left from lock to lock five to ten ‘After checking hydraulic system, times. Carefully check fluid leakage add fluid as necessary, then complete. with steering wheel held at each lock ly bleed air out of system. position for five seconds. CAUTION: Do not hold steering wheel at lock Bleeding hydraulic system position for more than fifteen seconds 1, Raise front end of vehicle until —atat wheels clear ground. INSPECTION AND 2. Rum engine, ADJUSTMENT Make sure temperature of fluid in pump rises to 60 to 80°C (140 to Wash clean all disassembled parts 176°F) with a temperature indicator. in suitable cleaning solvent and check 3. Check fluid level, adding fluid if their condition, necessary. ‘Check sealing portion (O-ring at adjusting screw nut O-ring at sector shaft cover Sector shaft oil seals Rear housing oil seal O-rings at intermediate cover Discard any oil seals and Oxings which have once been removed. Replace oil seal and O-ring if sealing surface is deformed or cracked. Steering wheel turning rane oneck Steering gear turning torque 1. Park vehicle ons level dry surface measurement and set parking brake fimiy 1. Measure turning torque at 360° 2. Bring power steering fluid up to position. adequate operating temperature. [Ap- (1) Install steering gear on Tool. proximately 60 to 80°C (140 to 4. Rum engine for 3 to 5 seconds. 176°F)1. << Kvest00307 5. Stop engine, adding fluid if nec- A essary. 1 Wis easy to bring power ster 6 Quickly tum steering wheel all the fluid up to adequate operating tem- way 10 right and left ten times and _atature by idling engine and atthe lightly touch wheel seoppers. same time turning steering wheel 7._Check fluid level, adding fluid if ftom left to right for about two necoerary minutes. Alternatively, drive vehicle 8. Start engine a ide several miles. Repeat steps 4 through 8 until air Tites must be inflated to. normal will be bled from pump. Pressure sT162) Tum stub shaft all the way 10 ight and lft several times (3) Measure turning torque at 360° position from straight-head postion using Tool $10.4 in) ‘¢ Stub shaft can be tuned by wrap: ping vinyl tape around serration area of stub shaft and fitting wrench socket. © If it is beyond specification, gear ‘must be replaced as an assembly. Measure turning straight ahead position. (2) Set worm gear in a straight-head position, torque at Straight ahead position is a position where stub shaft is turned two turns bby 45° from lock position. (2) Measure Tool. turing torque using Tarn torque a aight aad position: 01-04 Nem (1-4 kg-em, 08 - 35 ingen ‘ghar than at 380” 3. After adjustment is completed, tighten lock nut. (29-35 kgm, 21-2846) ssro4s I they are not within specifications, replace gear assembly. DISASSEMBLY Before disassembly, measure turn: ing torque. If they are not within specifica: tions, replace stoering gear assembly. CAUTION: Each oil sealing parts and dust cover ‘once removed must not be used again. Adjusting screw lock nut Remove adjusting screw lock nut, and replace O-ring ving Look nut Copper washer / © Sector shaft oll seal 1. Install steering gear on Too! kv48100301 2, Set stub shaft in a straight-ahead position ‘Straight ahead position isa position where stub shaft is turned two turns by 45° from lock position. 3. Disconnect sector shaft coverbolt, Do not loosen adjusting screw lock rut. Do not turn lock nut unless neces sary; otherwise it will damage O-ring, resulting in an oil 4. Draw out sector shaft Knock out end of sector sh approximately 20 mm (0.79 in). (0:79 ia) 5. Pull out sector shaft by hand Attach plastic film to two bearings located inside gear housing while simultaneously pulling out sector shaft 50 that bearings will not drop into housing. staypower Steering Gear (Model: |S. 661) and Oi! Pump - STEERING SYSTEM 6. Remove snap ring Remove dust cover, special wash: ers and ol seal ‘Apply blade of screwdriver to oil seal lightly s0 that it will not damage inner side of gear housi Special washer A (Smal) 8. Remove O-ring Rear housing seal 1. Install gear on Toot KV48100301 2. Loosen (not remove) rear housing bolts About § mm (0.20 i) 3. Turn sector shaft clockwise slight: ly to raise intermediate cover through piston. 4. Tum stub shaft counterclockwise and place piston (worm gear) in its straight-ahead position. 5. Remove sector shaft Refer to Sector Shaft Seal for disas: sembly. 6. Remove rear housing bolts. 7, Pull out rear housing, intermed- ate cover with worm gear assembly. ving ~ CAUTION: &. When worm assembly is removed, piston may turn end come off Under its own weight. Hold piston to prevent it from turning. If piston-to-intermediate cover clearance exceeds 45 mm (1.77 in) bby loosening, recirculating ball wit be out of groove of worm: do not reinstall piston but replace the en. tire assembly. . Take care not to damage tefon rng at piston end when removing, 8, Remove rear housing, turn worm assembly upside down, and lightly tp stub shaft end on top of workbench, CAUTION: Do not strike shaft with a hammer or pry it with a screwdriver. 9, Remove rear housing oll seal.STEERING SYSTEM — Power Steering Gear (Model: IP.S. 561) and Oi! Pump 10. Remove O-ring on both sides of 2. Install O-rings on both sides of intermediate cover. intermediate cover with new ones. ‘© Apply @ thin coat of vaseline to new O-rings prior to their installa © Be careful not to install wroni O-rings as some of them resemble Intermediate cover ASSEMBLY Adjusting screw lock nut seal “nsert new O-ring into adjusting ‘exew lock nut. apply @ thin coat of vaseline to O-r ‘¢ Insert O-ring to make sure it fits into groove. 3, Fit tear housing onto intermedi ate cover with worm gear assembly. CAUTION: 4, Do not ttt bal bearing b. Make sure that Oct ‘truding or extruding. L najusting seem Tock nut ar housing seal 1. Install wear housing oil seal using Tool. Before installing oil seal, apply recommended multi-purpose grease to lips. Kvasioo910 nd KV48100920 4. Insert_worm gear assembly with fear housing and intermediate cover 37963} into gear housing CAUTION: 4. Be careful that teflon ring at piston end is not damaged dur of gear housing. bb. When worm assembly is halfway inserted, teflon ring is deflected. Insert remaining part of worm as- sembly paying particular attention. Take care not to damage teflon ring ‘on corner of sector hole, Be sure that teflon ring settes in its correct position, Crisscross fashion sT-19Power Steering Gear (Model: IP S. 56L) and Oil Pump CAUTION: 4. If bolts are tightened while worm assembly is tilted, inner seats will tbe damaged. Tighten bolts while assembly is level Hf worm assembly is tilted, stub shafts turning torque will be in- creased. b. Check Oxings to ensure that they do not protrude or extrude. 6. Install sector shaft into gear hous: ing. Refer to Sector Shaft Oil Seal for assembly. 7. Check turning torque, Refer to Inspection and Adjust- ment. Sector shaft oil seal 1. Press new oil seal and dust cover using Tool KV48100980. ‘© When installing, be sure to use new seal, dust cover and special washers © Before installing, apply a thin coat Cf vaseline to new oil seal and dust ia st-20 2. Install anew snap ring into gear housing. CAUTION: 4. Turn snap ring to make sure it fits into groove. b. Always install snap ring with its rounded edges facing oil seal, ‘Snap rng (face faces inward.) R face \\ Inside snap ring Outside STEERING SYSTEM Installing 94? 892 gs roge 3. Fit new O-ring into sector shaft ‘© Before installing, apply @ thin coat of vaseline to O-ring. ‘¢ Make certain that O-ring is installed properly, and not damaged by sec- tor shaft. 4, Set piston rack at straight-ahead position, ‘Tum piston rack about 10° to 15° toward yourtelf with your finger, This is for smooth insertion of sec: tor gear | 5. Wrap vinyl tape around setation ates of sector shat ‘The reece Ie hat vow tpe pe vents oil lip fom Being dom during insertion. ree 6. Gradually insert sector shaft into gear housing, being careful not to dam age ol seal. When inserting sector shatt into ‘gear housing, remove plastic film, Be careful not to drop bearings into gear housing. 7. Tighten sector shaft cover bolts, 28. 34Nm (29-35 Kem, ‘uring 8. Check steering gear torque. Refer to Inspection and Adjust ment. © If there is a great difference be ‘tween values of turning torque be fore and after disassembly, it must bbe assumed that some new problem has occurred. It will be necessary £9 replace the entire assembly.stl EERING SYSTEM ~ Steering Linkage GD: Mult purpose grease points Ds Nem (ke, fb) REMOVAL AND INSTALLATION 1, Jack up front of vehicle and support it on the safety stands. 2. Block rear wheels with chocks. 3. Remove pitman arm using Tool. 4. Remove relay lever assembly. STEERING LINKAGE 240 114. Tie rod oar 5-80, 47-38) oS @ 206-235 (210-240, 152-174) 5. Remove tie rod from knuckle flange using Tool. La@ 235-268 ‘When adjusting toc, 270, 195) tbe g ser209) 6. Install steering linkage in the re- verse order of removal @ : Piuman arm to sector shat VRB7OL models 235-265 Nm (240-27. kom, 174.195 fb) LPS. 86 models 137-177 Wm (14-1819, 101-130 fib) Relay od asembly to body frame 31-42 Nm (32-43 kgm, 23.31 fib) Tie rod to knuckle flange | 88-108 Nm (9.0- 11.0 kom, | 65-80 fe18) 7. After installing steering linkage, check wheel alignment, and if neces- sary, adjust, Refer to Section MA for adjust: sT-21‘Steering Linkage ~ STEERING SYSTEM DISASSEMBLY Tie rod assembly 1. Remove tie rod assembly from knuckle flange using Toot 11772520000. 2. Separate tie rod socket assembly from tie rod tube. 1 Tierod socket 4 Tie rod clamp assembly 5 Tierod socket 2 Terodclmp sembly 5. Te rod tube’ Relay lever assembly Loosen nut, and separate each part 1 Reba lever bracket 7 Relay lever cover bracket 2 Gasker 8 Bushing 3 Spring 9 Greate sal 4 Spring seat 10 Nut 5 Relay lever shaft 11 Cotter pin 6 Bushing st22 ASSEMBLY ‘Assemble steering linkage in the ro: verse order of disassembly, observing the following instructions. @. Apply multi-purpose grease to clearance between shaft and bracket, and to each sliding portion. Relay lve shaft Relay lever 7 racket nad Pi (Grease seal Spring © 208-235 Nw (210-2409, 192-174 #48) seria b. Press relay lever bushing and grease seal into bracket ‘Apply multipurpose grease be- ‘ween lips of grease seal. . Apply liquid packing to both sides fof gasket, and install rolay lover bracket cover. lever starting torque Less than 4.9 Nem (50 kg-em, 43 intb) Tie rod assembly When tie rod socket assembly and tie rod tube are separated, correctly adjust tie rod length. wie te Gsm an) BF, b s——— Standard length "A" betwean ball stud contre. 1.219 47.99) (tod clamp nut © 25-28Nm Unit: nm (in) (25-29 kom, 18-21 feb) ssTa14 INSPECTION Ball joint 1. When ball stud is worn or axial play exists, replace side rod socker with a new one 2. When dust cover is broken o: deformed, be sure 10 replace with | new one (rod assembly), Initial turning torque: Ball joint 1.0-4.9Nm (10-50 kgem, 8.7. 43.4 intb) Relay lever assembly Check grease seal for breakage, ‘wear or play, and if necessary replace, Initial turning torqu Less than 4.9 Nem (50 kg-em, 43 in-ib) Check tie rod socket assembly and tie rod tube for breakage, bend or crack, and replace with a new one if necessary Steering damper ‘Check oil leakage or damping force ‘of damper, and replace if necessary. 147 N (15 kg, 33 Ib) at 0.3 m (1.0 fr)/see. For Australia 657 -912N (67 -93 kg, 148 - 205 tb) at 0.3 m (1.0 fl/se0. Fixing location Check fixing location (nuts and cotter pins) for looseness, play breakage. When looseness or play found, check for wear on tapered portion of ball stud, pitman arm of relay lever assembly When reassembling each ball joist use new cotter pins.STEERING SYSTEM — Service Data and Specitications SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Bache ot ear op en (imstraghtaneed postion! 0-02 (0-008 = em i) seeing (Except pickwel Colpxe End play Between sector ha foun Middle East td aching eer) 908 Stancord si Except above sone —— tmm tin) | 0.01 -0.02 0.0004 -0.0012) Sern or mad vre7o. | _iss6u = ee uckoett | re number Tero wing ee ee ae eli townie to 1.575.100 aT aman | ire (00620. | 48213 80100 0800) Sewina amar Nt a7 8,38) 1 550-1575, (oost0- » | 48214 80100 | 0.0820) 1.526 1.880 INSPECTION AND ADJUSTMENT (o0e00- | 4221s a0100 Adhuting shi thickness at From wes fl turning ale Inne fe! oars 292-209 1500-1525 (oso | 48216 80100 ote whee oom | 275° 2050 oa) Herston B50) 1475.1 500 Minimum turing adie Po — (o.0s81- | 42217 gor00 (Wall to wall) m (ft) saad on 0.0891) ConaeToo| 888m) Tao ‘Steering wivee! axial play me (in) 010) bigryat — 0881) Sewing whet lay Ton tnd_| tev ihan a8 38) 7 i Approximately 0.40 (3/4) | Oitcanaciy | 160 ere Wer time 20) Pycger encima GEAR Most | approximately 0.45 (3/4) Model VRE7OL . Model IPS S6L Worm bring pretend @.12(031 047m ‘Wino wa 039-059 40-60,28-82) Oi pump berdetiacton — mm (in) | 8, 12(021-0470 Nem (kg-em, in-lb) 7 eas Steering whet turing force Yom beng prod sing (ateeumternce of steer whee) | Leu than 343 (2.5, 7.7 ‘ N (kg, tb) | Sera Ha ih 1.010099 re ‘pomp maximum premre 6266 688,70, ia toorsalem?, px) | 996) a ling pee Unit number orl omg eno eo wo nao 178) 0500 0107 | 48273 e210 oe ae TResronioty 0.200 0.0070) | 4274 a2100 Fuld capecity Plime ost | ygARRroninery Acjusing shim ticknes [0700 0.0030) | 48275 2100 ee are eee Mem tgcm,imib) | 07-1.207-12, tonezet |i 360° position from straight-ahead 61-104) 0.50 a020 | a7? 22100 ottion [Segoe oat acin epee Swogneanen poner Arcam | 94 9.411 -4,09-35) (eet igen, in) | 128 Ien 108 mb) ey haber tha 360 sv-23Service Data and Speciticavions - STEERING SYSTEM STEERING LINKAGE TIGHTENING TORQUE = we] we [=e Eats ‘STEERING COLUMN (Model 160 series) Except at to-a9 [10-60 | arma nm em im mmitan [men | Loves | [amnnanmien | 29-0 [aa-00 wiry lover 49 50 43 fae ia . xt woe rcten | aaa se wana [038-048 ep ounenr Tena ing bracket —_ 18 Stal meat oa [aon Vibration, STEERING GEAR simmying el vaa7ou vse | tate (Greats | eee [sive |eneae [ae Phenom nas. 66 [240-270 | 174-198 | 197-177 | Wace] vo 0 Sewing pr houg to body rome wv [soon [erm [eee | e500 [ean t—— etic pull Secor salt over a nig we [reas [iis | ae | 2998 [ava te ar ver wna a2a7 [war mae [aaa fie itor nev Seco alt adoing wow oe at 09 [2040 | 22.2 | a0.a | 20.38 [ame He Oi pur we tke zs a = [we [2ra7 [oom ew ol pane eae = [x | 20-80 | 22-08 Stevia o homs Sn [Ce | ae | cana | oe STEERING LINKAGE — ee eB Barve wou [47-65 | one Yared edn we Tare we [esa | «7-00 ee ak 00 208 [210-240 | 2170 ay eae 7 aioe ws [sess | oom sT-24STEERING SYSTEM — rouble Diagnoses and Corrections TROUBLE DIAGNOSES AND CORRECTIONS Except for the following probable causes and corrective actions, refer to {rouble Diagnoses and Corrections in Front Axle and Front Suspension section. MANUAL STEERING Condition Probable cause Corrective action Excessive wheel play, Insufficiently tightened or improperly in stalled steering gear housing. Damaged steering linkage or ball joint. Incorrect adjustment of steers gear Retighten, Replace faulty parts. Adjust Vibration, shock or shimmying of steering wheel Insufficiently tightened or improperly in stalled steering gear housing ‘Wear of steering linkage. ‘Damaged relay lever assembly. Wor column beating, weakened column bearing. spring, or loose clamp, Retighten, Replace faulty parts. Replace. Replace or retighten. Vehidle pulls to right or eh. Deformed steering linkage and/or suspension link. Replace. Stif or heavy steering wheel Insufficient lubricants or mixing impurities in steering linkage or excessively worn steer ing linkage Worn or damaged steering gear and bearing, Incorrectly adjusted steering gear Deformed steer ig linkage. Interference of steering column with turn signal switch, Replenish grease or replace the part Replace Adjust. Replace. Adjust ST-25Trouble Disgnoses and Corrections ~ STEERING SYSTEM POWER STEERING Condition Probable cause Corrective action Oil pressure does not build up. Pump drive belt sippi Pump malfunctioning, Oil leaking through hose joints. oon pulley. il leaking through power steering, Readjust belt tension. Replace Replace or retighten copper washer. Replace sealing parts at steering gear Steering wheel moves heavily Lack of oil in oil pump,* Air present in ol Oil pressure too low. Wheel alignment out of specifications or air pressure in tires too low.* Steering gears improperly engaged.* ‘Steering column out of alignment. Wor or damaged ball joint at suspension and steering linkage.* Relay lever dragging.* Refill Bleed air. See “Hydraulic system check” Resalign or inflate tires to correct pressure Replace gear assembly Repair or replace Replace. Repair or replace. Steering wheel fils to Refer to items maeked “*" above. Front wheel caster improperly adjusted, Internal gears dragged or gouged. Readjust Replace gear assembly, Steering effort is not the same in both directions. Unstable running Oil leakage in steering geat Stuffy oil passage in steering gear. ‘Wheel bearing not properly adjusted Stuck or damaged control valve in steering ear Front whee! alignment not properly Excessive steering gear play. Play at suspension and linkage bal joint, Replace sealing parts, Replace gear assembly Readjust Replace gear assembly Readjust Readjust backlash or replace gear assembly. Replace. Noisy pump. Lack of oil in oil pump. Hoses or oil filter clogged, Loose pulley, Belt noisy or slapping. Broken pump part. Refill Clean or, if necessary, replace, Repair. Readjust tension, Replace. S126Radaeee eee ee POWER STEERING T Condition Probable cause Oil pressure does not build up, Pump drive belt slipping on pulley Pump malfunctioning Oil leaking through hose joints, Oi leaking throug Lack of oil in oil pump.* th power steering Steering wheel moves heavily Ait present in oil | Oi pressure t00 tow | Wheel alignment out of specifications or air Pressure in tires too low.* | Steering gears improperly engaged.* Steering column out of alignment. Worn or damaged ball joint at suspension | and steering linkage.» Relay lever dragging.* | | | —{— Corrective action Readjust belt tension, Replace Replace or retighten copper wash Replace sealing parts at stering g Refi Bleed air. See “Hydraulic system check’ Resign or inflate tires to correct Replace gear assembly Repair or replace. Replace Repair or replace. pegs Sizrne wheel fails o | Refer totems marked "* ahora vetura | Front wheet ster improperly adjusted Readjust Internal gears dragged or gouged | Replace gear assembly ane Stuffy oil passage in steering gea | Replace gear assembly Unstable running | Wheel bearing not properly adjusted Stuck or damaged ear control valve in steering Front wheel alignment not properly Excessive steering gear play Play at suspension and linkage bal joint Noisy pump, Lack of oil in oil pump, Hoses or oil filter clogged. Loose pulley, Belt noisy or slapping | eoten pump ST-26 Readjust Replace gear assembly Readjust Readjust backlash or replace gear Replace Refill Clean or, if necessary, replace Repair Readjust tension. Replace. assemblySTEERING SYSTEM — Special Service Tools SPECIAL SERVICE TOOLS [___Gaitappicaion ool number Tool name , “ Model VRB70L | Model LPS. 56L 23020001 | Sieg param paler a at x x eu es ST27180001 Steering whee puller x x T72750000 Stering ball joint remover x x 131278000 Preload gauge Oa "Torque wrench ace Socket adapter Gis Socket adapter : : eoeg-e ‘827091000 Pressure gauge ae |. x shutoft Kv48100301 Steering gear housing attachment x x Kv48100980 i seal dit set, @® Kv48100910 Drift @ Kv4si00920 Adapter @ @® Kv4s100930 ‘Adapter S x | 8) i eZ 8133210000 Gear cartier side bearing drift EF x st.27